PSD-3-148 WIRING/HARNESS & PROBES See page 8 PROPANE GAS TRAIN ASSEMBLY See page 6 COMMERCIAL POWER BURNER BOILER REPLACEMENT PARTS LIST COPPER BOILERS FOR HYDRONIC HEATING & HOT WATER SUPPLY LEGEND MODELS LW/LB: 1000 SERIES 980, 981 JACKET/FRAME ASSEMBLY See page 4 NATURAL GAS TRAIN/BLOWER ASSEMBLY See page 5 CONTROL BOARD See page 7 WATERWAYS & COMBUSTION CHAMBER See page 2 BY-PASS See page 6 EXHAUST & DRAIN ASSEMBLY See page 3 WATER INLET See page 3 A.O. SMITH WATER PRODUCTS CO., INC. 5621 W. 115TH STREET ALSIP, ILLINOIS 60803 Phone: 1-800-433-2545 Fax: 1-800-433-2515 Website: www.hotwater.com/parts PRINTED IN U.S.A. 1001 1 210654-000
1000 WATERWAYS & COMBUSTION CHAMBER PARTS LIST Part Number 1... Bracket... 191602 2... Burner and Cone Assembly... 191850-2 3... Combustion Chamber Asembly... 192129-1 4...Connector, Hose... 191765 5... Coupling, Flexible w/gasket...191780-1 6... Cover Outer... 210404 7... Gasket, Outer... 191563-1 8... Gasket, Burner... 191564-1 9... Gasket, Inner... 191563 10... Housing Assembly...191627-4 11... Ignitor... 192334 12... Insulation, Burner... 191618 13... Nut, Manifold...191555-1 14... O-Ring...191556-2 15... Probe, Outlet Temp./ECO... 210572 Part Number 16... Probe, Inlet Temp... 210571 17... Screw, Machine #8-32/ 3/8" Long, SST.. 210444 18... Screw, Machine #8-32/ 1" Long, SST... 191770 19... Sealer, Silicone (not shown)... 191482-1 20... Sensor, Flame... 210421 21... Spacer Ring... 191554-1 22... Switch, Safety Flow... 210176 23... Tee Assembly... 192387 24... Tube Assembly, Primary (LW Models)... 192388 24... Tube Assembly, Primary (LB Models)... 192225 25... Tube Assembly, Outlet... 210426 26... Tube Assembly, Secondary... 192386 27... Washer, Flat #8 SST... 191768 28...Restrictor-Air, Top Cover...191926-1 2
1000 EXHAUST, DRAIN & WATER INLET ASSEMBLY PARTS LIST Part Number Part Number 1... Clamp, Hose (Large)...191794-1 2... Clamp, Hose (Small)... 191794-3 3... Connector, Female Bulkhead... 191744 4... Connector, Port... 191745 5... Drain, Flange... 191620 6... Drain, Flange Assembly... 191625 7... Elbow... 191664 8... Gasket, Blocked Flue... 191767 9... Gasket, Drain... 191622 10... Gasket, Vent... 191683-1 11... Nipple... 20373-18 12... Nut, Hex 1/4"... 191769 13... O-Ring... 191556-1 14... Plate, Drain Seal... 191626 15... Pump Ass'y, Circulator (LW Models)... 192203 16... Tube Assembly, Inlet (LW Models)... 192308 17... Tube Assembly, Primary (LB Models)... 192225 18... Tube Assembly, Primary (LW Models)... 192388 19... Tubing, Condensate... 191746 20... Tubing, Pressure... 191562 21... U-Bolt Assembly... 191938 22... Valve Drain... 26273 23... Vent Assembly... 210494 24... Vent Flange... 191685-5 25... Vent Flange Assembly... 191686-1 26... Washer, Lock 1/4" Stainless... 191771 27... Washer, Flat... 191766 28... Vent Support, Bracket... 192194 29... Vent, Restricting Ring (Series 981, LP).. 191923-1 3
1000 JACKET/FRAME ASSEMBLY 1... Bolt Machine 5/16-18"... 191358-2 2... Control Panel Assembly... 210601 3... Display Board... 210219 4... Frame Assembly... 210501 5... Gasket, Display... 210130 6... Grommet... 97951 7... Handle... 191802 8... Junction Box Assembly...190438-1 9... Junction Box Cover... 2233 10... Label, Control Panel...210561-1 11... Locknut, Star...1953 12... Locknut #6-32... 210207 13... Nipple, Chase... 41994 14... Nut, Lock Hex 5/16-18"... 97896 15... Panel Assembly, Left Side...191796-3 16... Panel Assembly, Right Side...191796-2 17... Panel, Lower Front...191805-1 18... Panel, Rear (Natural)... 192191 18... Panel, Rear (Propane)... 210020 19... Panel, Top Cover...191609-1 20... Plate, Rear Cover... 210214 21... Screw, Hex Head 5/16... 210125 22... Screw, Hex Head #6-32... 210206 23... Switch, Blower Prover... 191666 24... Switch, Blocked Flue... 191667 25... Switch, Rocker...191665-1 26... Support Bracket (Propane Only)... 210017 27... Transformer (100VA)... 210449 28... U - Bolt Assembly (Waterway)... 191938 29... Washer, Flat... 191359 30... Washer, Lock... 191480 31... Switch, Relay... 211546 4
1000 NATURAL GAS TRAIN/BLOWER ASSEMBLY 1... Blower... 192195 2... Blower Adapter Assembly...192215-1 3... Blower Manifold Assembly... 192217 4... Bracket, Blower... 210214 5... Clamp, Hose... 191794-3 6... Elbow, 1-1/4"... 192216 7... Elbow, Union 1-1/4"...86506-1 8... Flange, Observation Port... 191573 9... Gasket, Blower Air Inlet... 192213 10... Gasket, Burner... 191564 11... Gasket, Manifold... 191565 12... Gasket, Port (1/8" Thick)... 191576 14... Manifold Assembly - Air/Gas... 192309 15... Nipple, Close 1/8"... 191147-3 16... Nipple, Close Stainless...191772-1 17... Nipple, Tapped...86505-3 18... Nipple, 1-1/4" x 38 1/2"... 86505-28 19... Nipple, 1-1/4" x 28 3/4"... 86505-27 20... Nipple, 1-1/4" x 2"... 86505 21... Nipple, 1-1/4" x 3"...86505-2 22... Nipple, 1-1/4" x 4"...86505-6 23... Nut, Hex 1/4... 170272 24... Orifice, Air (Series 980 - Nat. Gas)... 192737-3... Orifice, Air (Series 981 - L.P. Gas)... 192737-2 25... Orifice, Union... See Orifice Table Below 26... Plug, 1/8" Pipe... 3348 27... Port, Observation Lower... 191572 28... Port, Observation Upper...191572-1 29... Screen, Air Inlet...192220-1 30... Screw, Cap 1/4"... 190960-2 31... Screw, Flathead #8-32 x 1/2"... 191542 32... Screw, Flathead #8-32 x 3/4"... 191542-1 33... Switch, Low Gas Pressure... 191149-1 34... Shutter, Blower... 192593 35... Shutter Flange... 192592 36... Tee, 1/8"... 40119 37... Tee, Pressure... 191633 38... Tubing, Pressure... 191562 40... U-Bolt Assembly (Gas Train)... 191938-3 41... Valve, Main Gas...78481-3 42... Valve, Firing... 3423-3 43... Valve, Solenoid Gas... 192189 44... Washer, Lock 1/4"... 1006 DETAIL BACK VIEW LEGEND ORIFICE TABLE Natural Propane Size Elevation Gas Gas (inches) (Feet) 192222 --- 0.555 0-2000 192222-1 --- 0.537 2001-3000 192222-2 --- 0.533 3001-4000 --- 192739 0.333 0-2000 --- 192739-1 0.329 2001-3000 --- 192739-2 0.325 3001-4000 5
1000 PROPANE GAS TRAIN ASSEMBLY 1... Valve, Main Gas, LP 981 Series... 77780 2... Regulator, LP 981 Series... 192460 3... Valve, Firing... 3423-3 4... Pipe Plug... 3348 5... Switch, Low Gas Pressure... 191149-3 6... Nipple, 1-1/4...86505-13 7... Nipple, 1-1/4... 86505-2 8... Nipple, 1-1/4... 86505-17 9... Elbow, Union 1-1/4... 86506 10... Elbow, 90 Street 1-1/4... 94516 11... Elbow, 90 1-1/4... 192216 12... Nipple, 1-1/4 w/tapping... 86505-32 13... Nipple, 1-1/4...86505-6 14... Nipple, 1-1/4... 86505-4 15... Tee, 1/8 NPT Branch... 192465 16... Connector, Angle 1/8... 1578 17... Bleeder, Tube... 210016 18... Bleeder, Tube... 192461 On LB models the circulating pump must be between the boiler inlet and the bypass (see figure below). LW Please models update have pump these mounted numbers inside the jacket. 1000 BY-PASS PARTS LIST 1... Ball Valve... 191935 2... Tank/Pump Kit (LW Models Only - Not Shown)... 210625 3... Hex Reducing Bushing (LB Only)... 91940-8 4... Flush Bushing (LB Only)...192163-2 5... Relief Valve (LW Model)... 98883-3... Relief Valve (LB Model)...210451-2 6... Strap, Cable (not shown)... 99592-2 7... Tee, Condensate...192040-1 8... Tee (For use w/relief valve):... LW Model... 78685-4... LB Model... 191584 9... Tee 2"x2"x2"... 191584 10... Tee 2"x2"x3/4"... 78685-4 11... Valve, Drain... 26273 12... Valve, Manual Shutoff... 3423-3 13... Vent Patch Assembly... 192161 14... Nipple (For use w/relief Valve)... LW Model...20373-12... LB Model... 92706-4 15... Clamp, Hose...191794-1 6
1000 CONTROL BOARD WHC 1502 Part Number 210128 1000 WIRING CHART COLOR GAUGE PART NUMBER *** White 14 41974 Black 14 99650 Green 14 41972 White 16 86580 Black 16 86578 Green 16 69058 White 18 170595 Black 18 170596 Green 18 170606 Blue 18 191719 Red 18 170603 Yellow 18 170604 Brown 18 170890 White/Red 18 191700 White/Yellow 18 191702 White/Black 18 191699 Black/White 18 191694 Yellow/Blue 18 191708 Red/Green 18 191717 *** Use dash number to indicate length of wire. Example: 20 inch long red wire would be expressed as 170603-20. 7
1000 TERMINALS 78468 99593-6 78469 191673 42573 210091 210152 99599-2 1000 WIRING AND HARNESS ASSEMBLY Ignition 210575 Tank Probe 210604 Power 210579-1 Pressure Flow Switch 210576 Gas Valve 210574 (-1 Propane) Transformer 210578 Blower 210609 Outlet Temperature Control/ ECO Assembly 210572 Inlet Temperature Control Assembly 210571 Tank Probe (LW Models) 210211-1 8